Assemblies and methods for monitoring cathodic protection of structures

ABSTRACT

Assemblies and methods for monitoring the cathodic protection of underground or submerged structures may include a coupon assembly including a conductive test coupon and a reference electrode for determining the voltage potential difference of the protected structure without substantially interrupting surrounding current sources. The reference electrode may be at least partially covered with an electrolytic material in electrical contact with the surrounding environment via a plug including a porous material. A method of installation of the assembly may allow a single technician to install the coupon assembly using a probe rod without extensive on-site excavation. The coupon assembly may be configured to seat securely with the probe rod for stability during installation, and release from the probe rob when the probe rod is separated from the coupon assembly and withdrawn from the ground, leaving the coupon assembly at a preselected depth or preselected distance from the protected structure.

PRIORITY CLAIM

This is a continuation of U.S. Non-Provisional application Ser. No.17/886,178, filed Aug. 11, 2022, titled “ASSEMBLIES AND METHODS FORMONITORING CATHODIC PROTECTION OF STRUCTURES,” which is a divisional ofU.S. Non-Provisional application Ser. No. 17/805,801, filed Jun. 7,2022, titled “ASSEMBLIES AND METHODS FOR MONITORING CATHODIC PROTECTIONOF STRUCTURES,” now U.S. Pat. No. 11,447,877, issued Sep. 20, 2022,which claims priority to and the benefit of U.S. Provisional ApplicationNo. 63/365,102, filed May 20, 2022, titled “ASSEMBLIES AND METHODS FORMONITORING CATHODIC PROTECTION OF STRUCTURES,” and U.S. ProvisionalApplication No. 63/260,622, filed Aug. 26, 2021, titled “MINIATURE IRERROR-FREE CATHODIC PROTECTION COUPON ASSEMBLY INSTALLED VIA PROBE,” thedisclosures of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to assemblies and methods for monitoringcathodic protection of underground or submerged structures and, moreparticularly, to assemblies and methods including a cathodic protectioncoupon monitoring assembly for monitoring the cathodic protection ofunderground or submerged structures.

BACKGROUND

Cathodic protection of metallic structures covered in an electrolyteassociated with soil or a fluid is an established technique for reducingthe rate of corrosion of the structure. Such cathodic protection may befacilitated by a cathodic protection system, which may use an electricalenergy source to provide a cathodic current distributed over the surfaceof the structure, which may take the form of sacrificial anodes AC-to-DCrectifiers, and/or direct DC sources (e.g., batteries, solar panels,etc.). Once the cathodic protection system has been implemented, theeffectiveness of the protection resulting from operation of the cathodicprotection system may be assessed by measuring the potential differencebetween the structure and a reference electrode associated with anassembly used to assess the effectiveness.

An assembly used to assess the effectiveness of the cathodic protectionsystem may simulate the conditions of uncoated bare metal of a knownsurface area on a structure that might normally result from a coatingdefect. In such a simulation, a metallic coupon may be used to measure apotential difference between the metallic coupon and the surroundingsoil or fluid, and may be compared to cathodic protection criteria forthe structure's material to determine whether an active corrosionprocess is occurring. Accurately measuring the true electric potentialdifference of the structure, however, has often been difficult, forexample, due to errors or offsets resulting from nearby current sources,which may include otherwise uninterruptible sources, such as sacrificialanodes directly bonded to the protected structure, foreign rectifiers,stray currents, etc. For example, for situations in which severalrectifiers protect the structure, it may be necessary for all therectifiers to be interrupted simultaneously in order to obtainmeaningful measurements that are not effected by current associated withthe rectifiers. In addition, the time window with which to measure thepotential difference may be relatively brief because, for example, theamount of time between current interruption and depolarization (i.e.,the effects of the current as the structure de-energizes and dischargesits electric charge) may vary from several seconds to just a fraction ofa second, depending on the characteristics of the structure protected bythe cathodic protection system and/or the surrounding environment.Furthermore, capacitive spikes that may occur shortly after current isinterrupted may also mask the true potential difference intended to bemeasured.

In an effort to address these challenges, a reference electrode may beincorporated adjacent the metallic coupon in the cathodic protectionsystem. The reference electrode may allow a technician to obtainerror-free structure-to-electrolyte (or potential difference)measurements without a need to interrupt or disrupt nearby currentsources. The potential difference may thus be measured reliably withoutneeding to disrupt the current associated with operation of the cathodicprotection system to facilitate measurement of the potential differenceand/or without knowing the exact soil or fluid conditions and resistancein the vicinity of the measurements.

Existing assemblies used for monitoring the protection of underground orsubmerged structures, due to the size of the assemblies, may oftenrequire installation in the ground via mechanical excavation, hydroexcavation, and/or hand digging. These processes may be costly,labor-intensive, unduly time consuming, and may risk damaging thestructure. Additionally, these assemblies may often be fragile or easilydamaged due to the materials used to construct some of the components.Further, many standard assemblies may utilize a liquid electrolyte foroperation. Such electrolytes, due to their fluid nature, may berelatively easily added to the assembly, but may be susceptible toleakage, unless the assembly includes effective sealing at componentinterfaces, which may be complex and susceptible to degradation, which,in turn, may result in premature failure, thereby reducing the servicelife of the assembly once it has been buried in soil or submerged.

Accordingly, Applicant has recognized that there may be a desire toprovide improved assemblies and methods for measuring the effectivenessof a cathodically protected structure through error-free potentialmeasuring methods that improve the accuracy and/or reliability of theassembly while being relatively easier to install and/or maintain. Thepresent disclosure may address one or more of the above-referencedconsiderations, as well as possibly others.

SUMMARY

As referenced above, it may be desirable to provide improved assembliesand methods for evaluating the error-free potential of a cathodicallyprotected structure that is at least partially buried or submerged thatmay be more practicable, more efficient, less time consuming, and/orless labor-intensive to use. For example, there may be a desire toaccurately measure the potential difference without interrupting anexisting protective current or other current sources using a relativelymore durable construction for the assembly. Furthermore, the assemblymay be more easily installed by an individual technician. In someembodiments, the assemblies and methods may provide one or more of thesecapabilities for a variety of at least partially buried or submergedstructures such as, for example, pipelines, storage tanks, offshoreplatforms, well casings, etc.

In some embodiments, a cathodic protection monitoring assembly toenhance monitoring of a cathodic protection system of a structure atleast partially underground or submerged may define a longitudinal axisand include a first fitting. The first fitting may include an outersurface having an outer surface dimension sized to be greater than orequal to an outer rod surface dimension of a probe rod having a size andshape to facilitate placement of a portion of the cathodic protectionmonitoring assembly adjacent the structure. The first fitting furthermay include an inner surface having an inner surface dimension sized tobe less than an inner surface dimension of a rod cavity of an end of theprobe rod. The first fitting also may include an opening extendingthrough the first fitting along the longitudinal axis. The cathodicprotection monitoring assembly further may include an electricallyconductive test coupon seated adjacent the first fitting. Theelectrically conductive test coupon may define a hollow interior. Thecathodic protection monitoring assembly also may include an electricallyconductive connector at least partially received in the hollow interiorof the electrically conductive test coupon, and a wire bundle includinga first wire and a second wire extending along the longitudinal axisthrough the hollow interior of the electrically conductive test couponand the first fitting. The cathodic protection monitoring assemblyfurther may include a plug disposed adjacent the electrically conductivetest coupon. The plug may include a porous material and have a plugcavity. The cathodic protection monitoring assembly also may include areference electrode connected to a distal end of the second wire. Thesecond wire may facilitate an electrical measurement of the referenceelectrode. The cathodic protection monitoring assembly further mayinclude a second fitting including a proximal end sized to fit at leastpartially within the plug cavity of the plug and a distal end includinga fitting chamber configured to be at least partially filled withelectrolyte, such that the reference electrode is at least partiallycovered with the electrolyte.

In some embodiments, a cathodic protection monitoring assembly toenhance monitoring of a cathodic protection system of a structure atleast partially underground or submerged, may define a longitudinal axisand include a probe rod, including an elongated rod member extendingbetween a first rod end provided with a grasping portion and a secondrod end at least partially defining a rod cavity. The second rod end mayinclude an outer rod surface having outer rod surface dimension. Thecathodic protection monitoring assembly further may include a firstfitting adjacent the second rod end and including an outer surfacehaving an outer surface dimension greater than or equal to the outer rodsurface dimension of the probe rod. The first fitting further mayinclude an inner surface having an inner surface dimension less than aninner surface dimension of the rod cavity of the second rod end, and anopening extending through the first fitting along the longitudinal axis.The first fitting may be sized and dimensioned to be connected to therod cavity. The cathodic protection monitoring assembly also may includean electrically conductive test coupon seated adjacent the firstfitting. The electrically conductive test coupon may define a hollowinterior. The cathodic protection monitoring assembly further mayinclude an electrically conductive connector at least partially receivedin the hollow interior of the electrically conductive test coupon, and awire bundle including a first wire and a second wire extending along thelongitudinal axis through the hollow interior of the electricallyconductive test coupon, the first fitting, and the probe rod. Thecathodic protection monitoring assembly also may include a plug disposedadjacent the electrically conductive coupon. The plug may include aporous material and having a plug cavity. The cathodic protectionmonitoring assembly further may include a reference electrode connectedto a distal end of the second wire. The second wire may facilitate anelectrical measurement of the reference electrode. The cathodicprotection monitoring assembly also may include a second fittingincluding a proximal end sized to fit at least partially within the plugcavity of the plug and a distal end including a fitting chamberconfigured to be at least partially filled with electrolyte, such thatthe reference electrode is at least partially covered with theelectrolyte.

In some embodiments, a cathodic protection monitoring assembly toenhance monitoring of a cathodic protection system of a structure atleast partially underground or submerged may include a probe rod and afirst fitting. The probe rod may have an elongated rod member extendingbetween a proximal rod end and a distal rod end at least partiallydefining a rod cavity sized to connect with the first fitting. Thecathodic protection monitoring assembly also may include an electricallyconductive test coupon seated adjacent the first fitting with a hollowinterior extending therethrough and in communication with a hollowinterior of the first fitting. The cathodic protection monitoringassembly further may include an electrically conductive connector atleast partially positioned within the hollow interior of theelectrically conductive test coupon, and a plug having a plug cavityadjacent to the electrically conductive test coupon. The cathodicprotection monitoring assembly additionally may include a referenceelectrode connected to a distal end of one or more wires extendingthrough the hollow interior of the electrically conductive test couponand the first fitting. The cathodic protection monitoring assembly mayalso include a second fitting with a proximal end sized to fit at leastpartially within the plug cavity of the plug and a distal end includinga fitting chamber. The fitting chamber may be configured to be at leastpartially filled with electrolyte, such that the reference electrode maybe at least partially covered with the electrolyte.

In some embodiments, a cathodic protection monitoring assembly toenhance monitoring of a cathodic protection system of a structure atleast partially underground or submerged may include a probe rod and afirst fitting. The probe rod may have an elongated rod member extendingbetween a proximal rod end and a distal rod end at least partiallydefining a rod cavity sized to connect with the first fitting. Thecathodic protection monitoring assembly also may include an electricallyconductive test coupon seated adjacent the first fitting with a hollowinterior extending therethrough and in communication with a hollowinterior of the first fitting. The cathodic protection monitoringassembly further may include an electrically conductive connector atleast partially positioned within the hollow interior of theelectrically conductive test coupon, and a plug having a plug cavityadjacent to the electrically conductive test coupon. The cathodicprotection monitoring assembly may also include a second fitting with aproximal end sized to fit at least partially within the plug cavity ofthe plug and a distal end including a fitting chamber. The fittingchamber may be configured to be at least partially filled withelectrolyte.

In some embodiments, a method for installing a cathodic protectioncoupon monitoring assembly to monitor cathodic protection of an at leastpartially buried structure or an at least partially submerged structure,may include passing lead wires from a coupon assembly through a proberod. The coupon assembly may include an electrically conductive testcoupon and a reference electrode, and the probe rod may include anelongated rod member extending between a first rod end provided with agrasping portion and a second rod end at least partially defining a rodcavity. The method further may include engaging the coupon assembly withthe rod cavity at the second rod end of the probe rod, and tensioningthe lead wires to stabilize the coupon assembly at the second rod end ofthe probe rod. The method also may include inserting the probe rod andthe coupon assembly to one or more of a preselected depth or apreselected distance relative to the structure, and releasing tension onthe lead wires. The method further may include withdrawing the probe rodfrom the preselected depth, leaving the coupon assembly at the one ormore of the preselected depth or the preselected distance. The methodalso may include connecting the lead wires to an electrical junction incommunication with a testing device configured to facilitate measurementof potential differences detected by the coupon assembly.

Still other aspects and advantages of these exemplary embodiments andother embodiments are discussed in detail herein. Moreover, it is to beunderstood that both the foregoing information and the followingdetailed description provide merely illustrative examples of variousaspects and embodiments, and are intended to provide an overview orframework for understanding the nature and character of the claimedaspects and embodiments. Accordingly, these and other objects, alongwith advantages and features of the present disclosure, will becomeapparent through reference to the following description and theaccompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and may exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the embodiments of the present disclosure, areincorporated in and constitute a part of this specification, illustrateembodiments of the present disclosure, and together with the detaileddescription, serve to explain principles of the embodiments discussedherein. No attempt is made to show structural details of this disclosurein more detail than can be necessary for a fundamental understanding ofthe embodiments discussed herein and the various ways in which they maybe practiced. According to common practice, the various features of thedrawings discussed below are not necessarily drawn to scale. Dimensionsof various features and elements in the drawings may be expanded orreduced to more clearly illustrate embodiments of the disclosure.

FIG. 1 is a schematic elevation view of an example cathodicallyprotected structure, including an example cathode protection assemblyand an example cathode protection monitoring assembly including anexample probe rod and coupon assembly, according to embodiments of thedisclosure.

FIG. 2 is a schematic partial perspective view of a portion of anexample coupon assembly, according to embodiments of the disclosure.

FIG. 3 is a schematic exploded view showing example components of theexample coupon assembly shown in FIG. 2 , according to embodiments ofthe disclosure.

FIG. 4 is a schematic partial perspective view of another example couponassembly, according to embodiments of the disclosure.

FIG. 5 is a schematic exploded view showing example components of theexample coupon assembly shown in FIG. 4 , according to embodiments ofthe disclosure.

FIG. 6 is a schematic side view depicting an example probe rod fittedwith an example driving tip, according to embodiments of the disclosure.

FIG. 7A is a block diagram of an example method for installing acathodic protection coupon monitoring assembly, according to embodimentsof the disclosure.

FIG. 7B is a continuation of the block diagram shown in FIG. 7A,according to embodiments of the disclosure.

DETAILED DESCRIPTION

The drawings include like numerals to indicate like parts throughout theseveral views. The following description is provided as an enablingteaching of exemplary embodiments, and those skilled in the relevant artwill recognize that many changes may be made to the embodimentsdescribed. It also will be apparent that some of the desired benefits ofthe embodiments described may be obtained by selecting some of thefeatures of the embodiments without utilizing other features.Accordingly, those skilled in the art will recognize that manymodifications and adaptations to the embodiments described are possibleand may even be desirable in certain circumstances. Thus, the followingdescription is provided as illustrative of the principles of theembodiments and not in limitation thereof.

The phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. As used herein, theterm “plurality” refers to two or more items or components. The terms“comprising,” “including,” “carrying,” “having,” “containing,” and“involving,” whether in the written description or the claims and thelike, are open-ended terms, in particular, to mean “including but notlimited to,” unless otherwise stated. Thus, the use of such terms ismeant to encompass the items listed thereafter, and equivalents thereof,as well as additional items. The transitional phrases “consisting of”and “consisting essentially of,” are closed or semi-closed transitionalphrases, respectively, with respect to any claims. Use of ordinal termssuch as “first,” “second,” “third,” and the like in the claims to modifya claim element does not by itself connote any priority, precedence, ororder of one claim element over another or the temporal order in whichacts of a method are performed, but are used merely as labels todistinguish one claim element having a certain name from another elementhaving a same name (but for use of the ordinal term) to distinguishclaim elements. Similarly, the term “proximal” is understood to meancloser to, or in the direction of, a technician or operator.Accordingly, “distal” is understood to mean a location or directiondistant to or directed away from the technician or operator.

FIG. 1 is a schematic view of example components of a cathodicprotection monitoring assembly 3 or monitoring the effectiveness of acathodic protection system 13, according to embodiments of thedisclosure. As shown in FIG. 1 , the cathodic protection monitoringassembly 3 may include an example probe rod 20 and coupon assembly 100.In some embodiments, the coupon assembly 100 may be an IR error-freecoupon assembly. The example coupon assembly 100 may be configured tofacilitate potential difference measurements for a structure 2 that issubject to cathodic protection by the cathodic protection system 13 andis at least partially buried in the ground 1 or submerged in a fluid.The cathodic protection system 13 may provide cathodic protection, forexample, using a sacrificial anode 4 electrically connected to thestructure 2 by a conductor 6, such as a cable. In some embodiments, thecathodic protection monitoring assembly 3 may be configured to providepotential difference measurements that are “instant off” in natureand/or substantially free of voltage drop error. In some embodiments,the probe rod 20 may be used in soil applications and may include anelongate rod member 22 extending between a proximal or first rod end 26and a distal or second rod end 27. A transverse handle or graspingportion 24 may be located at or near the first rod end 26 to provide atechnician using the probe rod 20 with enhanced leverage and/or torquefor driving the probe rod 20 into the ground 1. In some embodiments, thegrasping portion 24 may include a T-handle, for example, as shown inFIG. 1 . The elongate rod member 22 may at least partially define aninner cavity 30 (see, e.g., FIG. 3 and FIG. 5 ) passing therethrough.The cavity can be circular, square, hexagonal, or other shape asappropriate for the application.

The probe rod 20 may be used to stabilize and insert the coupon assembly100 into a pilot hole 5 excavated in the ground 1 adjacent to thestructure 2. The coupon assembly 100 may be configured to engage thesecond rod end 27 of the elongate rod member 22 during assembly of thecoupon assembly 100 with the probe rod 20 for installation of the couponassembly 100 in the ground 1. For example, the elongate rod member 22may be a cylindrical or tubular structure defining the inner cavity 30,which may be a bore or cavity through which the wire bundle 104 may passfrom the coupon assembly 100 through the second rod end 27 to andthrough the first rod end 26. In some embodiments, the second rod end 27of the elongate rod member 22 may serve to stabilize the coupon assembly100, for example, when the coupon assembly 100 is introduced into theground 1 at a testing site location. The wire bundle 104 may containelectrical conductor cables 8 and 9 electrically connecting to a voltagemeasuring device 12, for example, at a test station 10, as shown in FIG.1 . In some examples, the voltage measuring device 12 may include one ormore switching devices for electrically connecting and/or disconnectingportions of the coupon assembly 100 to the voltage measuring device 12(e.g., at the test station 10). The switches can allow portions of thecoupon assembly 100 to be energized or isolated independent of the teststation 10 and/or the structure 2. For example, one or more actuatingswitches (e.g., switches 14 and 15 shown in FIG. 1 ) may allow at leasta portion of the coupon assembly 100 to be polarized relative to avoltage associated with the structure 2 through an electrical conductor7 without electrically disconnecting the anode 4 of the cathodicprotection system 13. For example, the coupon assembly 100 may beisolated from the structure 2 and/or test station 10 to be measuredindependently relative to a separate calibration electrode.

The coupon assembly 100, in at least some embodiments, may be used for avariety of structures set up in a variety of different environments. Forexample, on land the cathodically protected structure 2 may be atransmission pipeline or storage tank that is at least partially buriedin the surrounding environment (e.g., soil 1). In other examples, thestructure 2 may be an offshore pipeline or production rig asset that isat least partially submerged in an aqueous or other fluidic environment.One of skill in the art will appreciate that the design of a couponassembly 100 may be at least partially influenced by characteristicsassociated with the intended surrounding environment, which are notmeant to be limiting. Although most often referred to herein in thecontext of a structure 2 buried in soil 1, as shown in FIG. 1 , thedisclosed examples and methods may be used for any environmentcontaining a structure subject to cathodic protection.

When buried in soil, for example, the protected structure 2 mayrepresent a low-resistance path for stray electric currents, which tendto enter a structure at a discrete point and leave at another discretepoint. Stray currents flowing in the vicinity of the structure 2 and/orthe coupon assembly 100 itself may provide sources of voltage droperror, which may be proportional to magnitude of the current and/orresistivity of the soil 1. The soil 1 may often include a number ofsources of undesirable stray current, such as, for example, foreigncathodic protection installations, transit systems, foreign rectifiers,welding operations, electrical power transmission systems, etc. Anability to conduct “instant-off” potential measurements at the teststation 10 using the coupon assembly 100 without needing to interruptsuch current sources (and their associated electric potential) may be abeneficial attribute of at least some embodiments of coupon assembliesdisclosed herein.

FIG. 2 and FIG. 3 illustrate perspective and exploded views,respectively, of an example coupon assembly 100 (e.g., an IR error-freecathodic protection coupon assembly) for monitoring and accurateassessment of cathodic protection systems, such as the cathodicprotection system 13 (for example, structure 2, anode 4, and conductor 6shown in FIG. 1 ). The coupon assembly 100 may include a series ofcomponents that may be substantially concentric with or axisymmetricabout a longitudinal axis 111 of the coupon assembly 100. All or nearlyall the components may have a hollow central channel or bore throughwhich lead wires 124 and 125 of the wire bundle 104 (FIG. 3 ) may pass,for example, through the coupon assembly 100 and the elongate rod member22 or shaft of the probe rod 20. The wire bundle 104 may be ofsufficient length to allow it to exit the first rod end 26 of the proberod 20 and connect with a voltage measuring device and/or test stationfor measuring potential difference, for example, the voltage measuringdevice 12 and/or test station 10 shown in FIG. 1 .

In some examples, the coupon assembly 100 may include a first fitting110, which in the embodiment shown, also may serve as an interface forstabilizing the coupon assembly 100 in the distal or second rod end 27of the elongate rod member 22 of the probe rod 20. For example, the wirebundle 104 may include an insulated cable and/or epoxy, tape, and/or awater-proof shrink wrap seal exiting the first fitting 110, for example,to prevent moisture ingress and/or provide strain relief for the wirebundle 104. Such construction may provide a seal and/or additionalreinforcement, and, in some embodiments, may be added after othercomponents of the coupon assembly 100 are assembled, for example, at ajob site. The first fitting 110 may include an annular arrangementincluding an outer ring 114 and an inner channel 116 separating aninternal plenum 117 from the outer ring 114. In some embodiments, thefirst fitting 110 may include an outer surface dimension 112 sized to belarger than an outer surface dimension 28 of the elongate rod member 22,for example, so that the second rod end 27 may fit within the plenum 117when the inner channel 116 is sized to insert into the inner cavity 30of the rod member 22. This example arrangement may facilitatelongitudinal force transmission when the coupon assembly 100 is insertedinto the ground 1 and pushed to a preselected or desired depth. Theannular fit with the rod member 22 of the probe rod 20 also may allow adegree of lateral support to react against bending loads, which mightotherwise prematurely damage the coupon assembly 100 or sever the wirebundle 104 during installation of the coupon assembly 100 into theground 1.

In some examples, the elongate rod member 22 of the probe rod 20 mayhave holes 31 and/or other perforations along the longitudinal length,as shown in FIG. 2 . The holes 31 may be used to stabilize the soil inand around the pilot hole 5 excavated by the probe rod 20 in the ground1 adjacent the structure 2 (see FIG. 1 ) by directing water injectedinto the probe rod 20 to the surrounding environment. This waterinjection may ensure the entirety of the column of the pilot hole 5 isstabilized for the subsequent installation of the coupon assembly 100into the pilot hole 5 to the preselected or desired depth.

The coupon assembly 100, in some embodiments, may include a test coupon120. The test coupon 120 may be metallic and/or electrically conductive,and may be inserted into the bottom portion of the first fitting 110,for example, as shown in FIG. 3 . The test coupon 120 may include ahollow cylinder including an outer surface 121 having a known orpreselected surface area. In some embodiments, when mounting the testcoupon 120 in the first fitting 110, complimentary surface features onthe test coupon 120 and/or the first fitting 110 may be used forsecuring the test coupon 120 and the first fitting 110 to one another,for example, instead of fasteners, which may corrode. In someembodiments, the first fitting 110 may include an extension of the innerchannel 116, which may be received in an inner cavity or hollow interiorof the test coupon 120. In some embodiments, in addition to, or insteadof, an extension of the inner channel 116, the first fitting 110 maydefine a recess for receiving at least a portion of the upper edge ofthe test coupon 120.

The test coupon 120, in some embodiments of the cathodic protectionmonitoring assembly 3, may be intended to simulate uncoated portions ofthe metallic structure 2 that is being protected by the cathodicprotection system 13. In such embodiments, material forming the coupon120 may be substantially matched to the uncoated base material of thestructure. For example, for use with buried storage tanks or pipes, thisbase material may often include or be a mild steel or similar alloy. Forexample, the material may be a mild 1018 low-carbon steel having goodcase-hardening qualities that may be well-suited to cold forming andbending techniques. Similar materials, such as A36 steel are alsocontemplated, as well as a number of alternative materials, dependingon, for example, the specific environment and/or characteristics of thestructure 2 that is buried or submerged.

In some embodiments, an intermediate fitting 130 may be secured to anend of the test coupon 120 opposite the first fitting 110. Theintermediate fitting 130 may be substantially annular and may define aninner channel portion 132 sized to fit within the interior of the testcoupon 120 and include an outer flanged portion 134 sized to closely fitaround the outer surface 121 of the test coupon 120 (see FIG. 3 ). Forexample, the space between the inner channel portion 132 and the outerflanged portion 134 of the intermediate fitting 130 may define areception space or pocket that is flush with the inner and outersurfaces of the test coupon 120. The inner channel portion 132 of theintermediate fitting 130 may also at least partially define a centralbore configured to allow the passage of one or more of the lead wires124 and 125 therethrough.

The test coupon 120 may act as a polarized element, and the outersurface 121 may have a surface area sized for specific testing-relatedpurposes. For example, the exposed outer surface area of the outersurface 121 of the test coupon 120 may be dimensioned to facilitatetesting-related calculations of characteristics of interest, such as,for example, corrosion-related characteristics including corrosionrates. For example, the outer surface area of the outer surface 121 maybe about ten square centimeters, which may be a convenient surface areasize for such calculations. Other outer surface area sizes arecontemplated, which may be used, for example, in environments wherespecific potentials or current densities are expected to be encountered.In some examples, other outer surface area sizes are contemplated, whichmay depend on the relative size or sizes of coating defects anticipatedon the surface of the structure being cathodically protected. In someexamples, a test coupon 120 may have an outer surface 121 with a surfacearea of about one square centimeter sized in accordance with expectedcoating defect sizes for a structure with a newer and/or higher qualitycoating. In some examples, a test coupon 120 may have an outer surface121 with a surface area of about 100 square centimeters sized inaccordance with expected coating defect sizes for a structure with alesser quality coating or a situation where damage to the coating of thecathodic protection system 13 may be suspected.

In some embodiments, one or more additional test coupons 120 may beincorporated into the coupon assembly 100, and the one or moreadditional test coupons 120 may have different sizes, electricalconductivities, compositions, etc., for example, depending on thecharacteristics of the structure 2 and/or the surrounding environment.For example, one or more additional test coupons 120 may be usedtogether, and each of the one or more additional test coupons 120 mayhave respective surface areas of about one square centimeter, ten squarecentimeters, and/or 100 square centimeters.

In some embodiments, a coupon assembly 100 may have, for example, threeindividual coupons having multiple surface areas. For example, a firstcoupon may have a surface area of about one square centimeter sized tomeasure AC voltage and/or current density. A second and a third couponmay have the same approximate surface area (sized in accordance withexpected coating defect sizes for the structure) and may be used tomeasure DC voltage and/or current density. For example, the secondcoupon may have a surface area of about 10 square centimeters and may beconnected to the structure 2 being cathodically protected to obtain IRerror-free potential measurements. The third coupon may also have asurface area of about 10 square centimeters and be electrically isolatedfrom the structure 2. The third coupon may then be used, for example, toobtain native or “depolarized” measurements without having to detach anddepolarize the second coupon to obtain the same native measurements.

In some embodiments, the test coupon 120 and a first lead wire 124 (or asecond lead wire 125) may be electrically connected in the interior ofthe test coupon 120 via a conductive connector 122. In some embodiments,the conductive connector 122 may include a conductive coil. In someexamples, the first lead wire 124 and the second lead wire 125 may bebundled together, helically wrapped together, and/or insulated together.

In the environment surrounding the structure 2 under cathodicprotection, current may flow, for example, through the soil (and/orother electrolyte), through the structure 2 itself, and/or throughconductive cables or wires electrically connecting the structure to thetest coupon 120 of the coupon assembly 100. In some embodiments, thelead wires may include one or more additional conductors, for example,such that effects of electrical interference from flowing currents onpotential difference measurements may be reduced, minimized, oreliminated. For example, the first lead wires 124 may include twoconductors attached to the conductive connector 122; one of theconductors may be electrically connected to the structure 2 undercathodic protection and may carry current, and anotherseparately-insulated conductor may be electrically connected to apotential measuring device free from current load. In this exampleconfiguration, additional voltage drop error may thus be avoided bytaking potential difference measurements from the conductor that is notelectrically connected to the structure 2.

The first lead wire 124 may be electrically and/or physically secured tothe conductive connector 122 to provide a strong electrical connection.In some embodiments, the first lead wire 124 may be wrapped tightlyaround the conductive connector 122, and in other embodiments, the firstlead wire 124 may be directly connected to the conductive connector 122via soldering (e.g., via lead solder) and/or a brazed connection. Insome examples, the conductive connector 122 may be oriented transverserelative to the longitudinal axis 111 of the coupon assembly 100, forexample, as shown in FIG. 3 . In some embodiments, the conductiveconnector 122 may include windings of metallic wire or a strip ofmetallic material that may be longitudinally compressed to fittransversely in the inner cavity of the test coupon 120, for example,such that opposing ends of the conductive connector 122 are biasedagainst opposing sides of the inner cavity of the test coupon 120. Thisexample configuration may serve to secure the position of the conductiveconnector 122 inside the inner cavity of the test coupon 120 andmaintain electrical contact with the inner cavity of the test coupon120. In some embodiments, it may not be necessary for the second leadwire 125 to be electrically connected to the conductive connector 122.The second lead wire 125 may be physically but not electrically securedto the first lead wire 124 (and/or to one or more other wires) in thewire bundle 104 and may be threaded through the inner channel 116 of thefirst fitting 110 in a direction toward the conductive connector 122. Insome embodiments, heat shrink tubing may be provided over some or all ofthe wire bundle 104 and/or any electrical connections, for example, toimprove the electrical insulation and durability associated with thewire bundle 104.

With the electrical connections made (and any wire insulation and/orheat shrink tubing secured), the inner cavity of the test coupon 120 maybe filled with a hardenable filler (e.g., epoxy, adhesive, and/orplaster) and allowed to cure or harden and fix the locations of theconductive connector 122 and related components in the inner cavity ofthe test coupon 120, which may also serve to provide strain relief andinsulation for the electrical connections. The hardenable filler alsomay prevent the inner surface of the test coupon 120 from electricalconnection with the soil to prevent corrosion on the inner surface. Insome examples, the hardenable filler may also serve to secure physicalconnections between the test coupon 120 and the first fitting 110 andthe intermediate fitting 130. In some embodiments, the hardenable fillermay include a slow-cure epoxy (e.g., curable in a time period rangingfrom about thirty minutes to about twelve to twenty-four hours),including multi-part compounds of resin and hardener. Prior to fillingthe inner cavity of the test coupon 120, the hardenable filler may besubjected to low pressure or a vacuum, for example, to remove voids, airpockets, and/or moisture. The inner cavity of the test coupon 120 maythereafter be filled using, for example, a syringe or other similarmaterial injection device, such that electrical and/or physicalconnections between the conductive connector 122 and one or more of thelead wires 124 or 125 may be substantially or completely encapsulated,and the hardenable filler may be allowed to set to a semi-solid or solidstate.

The coupon assembly 100 may include a second fitting 150 connected tothe intermediate fitting 130 and/or to the test coupon 120. For example,as shown in FIG. 3 , the second fitting 150 may include a first orproximal end 152 at least partially defining a relatively smaller outersurface dimension (e.g., a diameter) than a second or distal end 154 ofthe second fitting 150. In some embodiments, the proximal end 152 of thesecond fitting 150 may include external threads 155 for cooperativethreaded engagement with the inner channel portion 132 of theintermediate fitting 130. Alternatively, or in addition, the secondfitting 150 and the intermediate fitting 130 may be secured to oneanother via, for example, a press fit, one or more set screws, and/oradhesives. The distal end 154 of the second fitting 150 may at leastpartially define an internal chamber or reservoir, which may be at leastpartially filled with an electrolyte material or solution. In someexamples, the proximal end 152 of the second fitting 150 may include oneor more holes 153 through a sidewall of the second fitting 150. The oneor more holes 153 may allow the electrolyte solution of the couponassembly 100 to be in electrical communication with the surrounding soilor fluid environment in which the structure 2 being protected ispresent. For example, as shown in FIG. 3 , the proximal end 152 of thesecond fitting 150 may include external threads 155 for cooperativelyengaging internal threads of the intermediate fitting 130, a plug 140,and/or other components of the coupon assembly 100.

In some embodiments, the distal end 154 of the second fitting 150 may beconfigured to be connected to a distal end cap 160 of the couponassembly 100. A water-resistant or water-tight seal may be providedbetween the distal end 154 of the second fitting 150 and the distal endcap 160. The water-resistant or water-tight seal may be provided bysealant, caulk, adhesives, gaskets, and/or other sealing jointconfigurations. The distal end cap 160 may include a tip 103 having aconical, pointed, and/or tapered shape, which may increase the ease ofinstalling the coupon assembly 100 into the ground, for example, bydisplacing material and/or debris as the coupon assembly 100 is insertedinto the ground. In some embodiments, the distal end cap 160 may beattached to the second fitting 150 via, for example, a threadedconnection, adhesives, and/or fasteners (e.g., one or more set screws).In the example shown in FIG. 3 , the distal end cap 160 includesinternal threads configured to engage complimentary external threads ofthe second fitting 150. The example threaded engagement between thedistal end cap 160 and the second fitting 150 may facilitate selectiveseparation and engagement between the distal end cap 160 and the secondfitting 150, for example, such that the distal end cap 160 may beremoved from the second fitting 150 for supplying electrolyte materialto the distal end 154 of the second fitting 150 to substantially orcompletely fill the distal end 154 with the electrolyte material. Insome embodiments, the distal end cap 160 may be formed integrally with(e.g., as a unitary component) the second fitting 150 and may not beeasily separated from the second fitting 150.

In some embodiments, the electrolytic material may include a liquidelectrolyte, a solid-state electrolyte, and/or an electrolyte having agel-like form. For example, a liquid electrolyte may render itrelatively easier to add electrolyte to the coupon assembly 100. In someembodiments, the coupon assembly 100 may include seal-like structuresand/or may be assembled using sealant to seal adjacent components toreduce the likelihood or prevent electrolytic material having a liquidform from leaking from the coupon assembly 100. In some embodiments, asolid-state electrolyte (e.g., a plaster impregnated with copper sulfate(CuSO₄) or similar material) may be used when, for example, the couponassembly 100 will be placed in an aqueous environment.

In some embodiments, at least a portion of the electrolytic material mayhave a gel-like form, which may reduce the likelihood or substantiallyprevent leakage of the electrolytic material from the coupon assembly100, which, in turn, may render the coupon assembly 100 relatively moredurable and/or may increase the service life of the coupon assembly 100,for example, as compared to a coupon assembly including solely liquidelectrolyte. For example, at least a portion of the electrolyticmaterial may include copper sulfate, water, a solid filler, mixturesthereof, and/or similar materials or materials having similarelectrolytic and/or gel-like characteristics, although otherelectrolytic materials are contemplated. The gel-like electrolyte mayinclude, for example, a liquid of distilled water supersaturated withcopper sulfate pentahydrate, a solid powder or aggregate of hydrophilicfumed silica as a thickener and/or solidifying agent, and powderedcopper sulfate pentahydrate to increase the concentration of coppersulfate and prolong the life of the electrolyte mixture. In someembodiments, the mixture may include approximately 1000 milliliters ofdistilled water supersaturated with copper sulfate (in a ratio having 2milliliters of distilled water per gram of powdered copper sulfatepentahydrate), 120 grams of hydrophilic fumed silica, and 150 grams ofpowdered copper sulfate pentahydrate.

As shown in FIG. 3 , in some embodiments, the coupon assembly 100 mayinclude a reference electrode 138 electrically connected to the secondlead wire 125 and suspended within the electrolytic material in areservoir or chamber of the second fitting 150, for example, tofacilitate potential difference measurements (e.g., instant-offpotential difference measurements). For example, in some embodiments,the second lead wire 125 may at least partially form the referenceelectrode 138. As shown in FIG. 3 , a portion of the second lead wire125 may be helically wrapped around itself to form a coil, which mayresult in an increased surface area for electrical connectivity. In someembodiments, the reference electrode 138 may include an electricallyconductive and/or metallic coil, an electrically conductive and/ormetallic strip, and/or an electrically conductive and/or metallic rod,and may be connected in a fixed relationship with the test coupon 120,which may be electrically conductive as described herein. In someembodiments, a metallic strip or rod of copper and/or zinc may be bondedto the second lead wire 125 and situated in the electrolytic material inthe second fitting 150. When combined with the electrolytic material,this example combination may facilitate measurement of potentialdifferences between the test coupon 120 and reference electrode 138 withan allowable tolerance per NACE Standard TM0211-2011, or having voltagedrop error limited to about ±10 millivolts (mV) or less.

In some embodiments, the plug 140 may be configured to at leastpartially encircle the proximal end 152 of the second fitting 150, forexample, between the intermediate fitting 130 and the distal end 154 ofthe second fitting 150. The plug 140 may be formed from a hydrophilicmaterial or hydrophobic material, and/or may have a defined porosity ora defined rate through which selected materials may flow through theplug 140. In some embodiments, the plug 140 may be configured to allowand/or wick moisture from the environment through capillary action tohydrate the electrolytic material, for example, via passage through oneor more holes 153 in the proximal end 152 of the second fitting 150,while, in some embodiments, preventing the electrolytic material fromescaping from the second fitting 150. The plug 140 may also allow thecoupon assembly 100 to be positioned in various orientations without therisk of leakage of the electrolytic material from the second fitting (orwith a relatively reduced risk of leakage). In some embodiments, atleast a proximal portion of the distal end 154 of the second fitting 150may include a chamfer, bevel, or recessed geometry, for example, toengage and/or locate the plug 140 with respect to the proximal end 152of the second fitting 150 (e.g., about the proximal end 152) when thecoupon assembly 100 is assembled. A distal end 154 of the second fitting150 may have an inner chamber, plenum, or reservoir with a volume, whichmay contain an electrolytic material and reference electrode 138.

The plug 140 may be formed from, for example, ceramics, clay-relatedmaterials, and/or other porous materials. In some embodiments,hydrophilic polymeric materials, such as, for example, high orultra-high molecular weight polyethylene, may form the plug 140. In someembodiments, at least some polymeric materials may be relatively moredurable and/or relatively less brittle than the ceramics and/orclay-related materials, and may result in the plug 140 being relativelyless likely to crack, chip, or be damaged when inserted into relativelycourse soils and/or environments including hazards, such as rocks orother buried materials. In some embodiments, the plug 140 may be formedfrom one or more materials having a defined porosity size correspondingto the average diameter of an individual pore in the material matrix.For example, the material of the plug 140 may have a porosity rangingfrom about 4 micrometers (μm) to about 20 μm, for example, from about 5μm to about 15 μm. In some embodiments the material may have a porosityof approximately 10 μm, although other porosity ranges and/or pore sizeranges may be contemplated, for example, depending on the specificcharacteristics of the soil or fluid in which the structure 2 ispresent.

In some embodiments, one or more of the components of the couponassembly 100 may be formed via, for example, three-dimensional printing.In some such examples, one or more of the components may be formed frommaterials via three-dimensional printing. For example, the first fitting110, the intermediate fitting 130, the second fitting 150, and/or thedistal end cap 160 may be formed via three-dimensional printing. In someembodiments, filaments of, for example, acrylonitrile butadiene styrene(ABS), polyethylene terephthalate (PET), and/or nylon may be used toform one or more of the components using a fused depositionthree-dimensional printing apparatus. In some embodiments, for example,UV-cured resins offering greater precision and density may be used toform one or more of the components using a stereolithographicthree-dimensional printing apparatus. Such materials may bewater-resistant, electrically insulating, and/or abrasion-resistant.Other manufacturing techniques and/or materials are contemplated, suchas, for example, injection molding, blank molding, and/or post-moldingmachining processes.

FIG. 4 and FIG. 5 are schematic perspective and exploded views,respectively, of another embodiment of the coupon assembly 200 (e.g., anIR error-free cathodic protection coupon assembly) for assessment ofcathodic protection systems, such as the example cathodic protectionsystem 13 shown in FIG. 1 . The example coupon assembly 200 shown inFIGS. 4 and 5 may be substantially cylindrical and may includecomponents concentric with or axisymmetric about a longitudinal axis 211of the coupon assembly 200. As shown in FIG. 5 , many of the examplecomponents may have a hollow central bore through which first and secondlead wires 224 and 225 of a wire bundle 204 may pass, including a shaft22 of a probe rod 20. The wire bundle 204 may be used for thedetermining cell potential measurements at a remote test station, forexample, as previously described herein with respect to FIGS. 1-3 .

As shown in FIGS. 4 and 5 , the example coupon assembly 200 may includea first fitting 210, which may connect the coupon assembly 200 to thedistal or second rod end 27 of the elongate rod member 22 of the proberod 20, and in some embodiments, may act to secure and/or stabilize thecoupon assembly 200 in the distal or second rod end 27. The firstfitting 210 may at least partially define reverse-hourglass-likegeometry including upper section 214 and a lower section 216 of arelatively smaller transverse dimension 213 (e.g., relatively smallerdiameters) than a transverse dimension 212 of a central region 215(e.g., transverse relative to the axis 211). For example, the centralregion 215 may define a first outer surface dimension 212 sized to belarger than an outer surface dimension 28 of the elongate rod member 22.In some embodiments, the first outer surface dimension 212 may be onlyslightly greater than the outer surface dimension 28 of the elongate rodmember 22 of the probe rod 20. In some embodiments, the first outersurface dimension 212 may range from about 0.250 inches to about 1.0inch, such as, for example, from about 0.35 inches to about 0.750inches, or for example, from about 0.375 inches to about 0.625 inches.In some embodiments, the first outer surface dimension 212 may rangefrom about 0.40 inches to about 0.60 inches (e.g., about 0.50 inches).Other sizes are also contemplated.

The first fitting 210 may include an upper portion 214 that at leastpartially defines a second outer surface dimension 213 sized to at leastpartially fit or be received within the cavity 30 of the elongate rodmember 22 of the probe rod 20, for example, such that the second rod end27 seats against the larger central region 215 (FIG. 5 ). This exampleconfiguration may facilitate longitudinal transmission of downward forceused, for example, when the coupon assembly 200 is inserted into in theground 1 for placement of the coupon assembly 20 adjacent the structure2 being cathodically protected. The upper portion 214 of the firstfitting 210, which may be received in the cavity 30 of the second rodend 27, may resist bending loads that may be transmitted from theelongate rod member 22 as the coupon assembly 200 is inserted into theground 1, which may stabilize connection between the coupon assembly 200and the elongate rod member 22 and/or substantially maintain theorientation of the coupon assembly 200 relative to the probe rod 20 asthe coupon assembly 200 is inserted into the ground.

Similar to examples shown in FIGS. 2 and 3 , the test coupon 220 (e.g.,a metallic, electrically conductive test coupon) may be connected to thelower section 216 of the first fitting 210. In some embodiments, thetest coupon 220 may include a hollow cylinder at least partiallydefining an outer surface 221 having a preselected or desired surfacearea. The test coupon 220 may be at least partially formed from anelectrically conductive material, such as, for example, mild 1018low-carbon steel or an alloy at least similar to an uncoated basematerial at least partially forming the buried or submerged structure 2being cathodically protected.

In some embodiments, an intermediate fitting 230 may be secured to anend of the test coupon 220 opposite the first fitting 210. Theintermediate fitting 230 may include a proximal upper portion 232 sizedto fit at least partially within an interior portion of the test coupon220, and an outer flange portion 234 sized such that the outer surface221 of a lower edge of the test coupon 220 is approximately flush withan outer surface of the outer flange portion 234.

As shown in FIG. 5 , the first lead wire 224 may be electrically securedto a conductive connector 222, and the conductive connector 222 may beelectrically contacted with an inner wall of the test coupon 220. Forexample, the first lead wire 224 may be electrically connected to theconductive connector 222 via soldering or brazing, providing both anelectrical and physical connection. As shown in FIG. 5 , the conductiveconnector 222 may be oriented transverse relative to the longitudinalaxis 211 of the coupon assembly 200. In some embodiments, the conductiveconnector 222 may include a conductive coil. For example, in someembodiments, the conductive connector 222 may include windings ofmetallic wire or a strip of metallic material that may be longitudinallycompressed to fit transversely in the inner cavity of the test coupon220, for example, such that opposing ends of the conductive connector222 are biased (i.e., spring loaded) against opposing sides of the innercavity of the test coupon 220. This example configuration may serve tosecure the position of the conductive connector 222 inside the innercavity of the test coupon 220 and maintain electrical contact with theinner cavity of the test coupon 220. In some embodiments, it may not benecessary for the second lead wire 225 to be electrically connected tothe conductive connector 222. The second lead wire 225 may be physicallybut not electrically secured to the first lead wire 224 (and/or to oneor more other wires) in the wire bundle 204 and threaded through aninner channel 217 of the first fitting 210 in a direction toward theconductive connector 222. In some embodiments, heat shrink tubing may beprovided over some or all of the wire bundle 204 and/or any electricalconnections, for example, to improve electrical insulation associatedwith the wire bundle 204.

As shown in FIGS. 4 and 5 , a plug 240 may be disposed adjacent theintermediate fitting 230. In some embodiments, the plug 240 may beformed from, for example, a porous material. The plug 240 may besubstantially cylindrical, although other shapes are contemplated. Insome embodiments, the plug 240 may be formed from polymeric compositionhaving preselected and/or defined porosity. In some examples, the plug240 may be formed ceramic and/or clay-related materials, which may beselected to provide limited passage of water or moisture from thesurrounding environment therethrough. Porosity characteristics at leastsimilar to those previously described herein may be selected, althoughother porosities are contemplated depending on, for example, theelectrolyte/environment combination specific to the cathodic protectionbeing assessed.

The example coupon assembly 200 may include a second fitting 250connected to the plug 240. For example, as shown in FIG. 5 , secondfitting 250 may include a proximal end 252 at least partially definingone or more holes 253 configured to receive moisture through the plug240 and into the second fitting 250. In some examples, the proximal end252 of the second fitting 250 may be inserted into an interior passage242 of the plug 240. In some embodiments, at least a portion of theproximal end 252 of the second fitting 250 may be secured to the plug240 via, for example, adhesives and/or other known securing methods. Insome examples, a threaded engagement or press-fit connection may be usedto secure the proximal end 252 of the second fitting 250 to the plug240. As shown in FIG. 5 , the proximal end 252 may at least partiallydefine a substantially cylindrical opening extending through at least aportion of the second fitting 250 to allow for the insertion and passageof a reference electrode 238 therethrough. A distal end 254 of thesecond fitting 250 may at least partially define a relatively largerouter dimension or diameter than the proximal end 252. The distal end254 may at least partially define an inner volume reservoir or chamberconfigured to receive an electrolytic material.

The reference electrode 238 of the coupon assembly 200 may beelectrically connected to the second lead wire 225 and suspended,encapsulated, or at least partially covered within the electrolyticmaterial in the reservoir or chamber of the second fitting 250. Thereference electrode 238 may be an electrically conductive coil, anelectrically conductive strip, an electrically conductive bar, anelectrically conductive ribbon, or another electrically conductiveconfiguration to provide strong electrical contact with the surroundingelectrolyte.

In some embodiments, the coupon assemblies 100 and/or 200 may berelatively compact in size, for example, ranging from about 2 incheslong to about 20 inches long (measured axially), from about 4 inches inlength to about 12 inches in length, from about 5 inches in length toabout 10 inches in length, from about 5 inches in length to about 8inches in length, from about 5 inches in length to about 7 inches inlength (e.g., about 6 inches in length). In some embodiments, the couponassembly 200 may range from about 0.25 inches in diameter or dimensionto about 1.0 inch in diameter or dimension, from about 0.33 inches indiameter or dimension to about 0.75 inches in diameter or dimension, orfrom about 0.40 inches in diameter or dimension to about 0.66 inches indiameter or dimension (e.g., about 0.50 inches in diameter ordimension). In some embodiments, a relatively compact size mayfacilitate ease of assessing the cathodic protection of a cathodicallyprotected structure 2 by, for example, making it possible for a singletechnician using simple hand tools to install a coupon assembly 200adjacent the structure 2 and perform measurements using the installedcoupon assembly 200. This may be repeated at multiple locations alongthe length of the structure 2.

Applicant has found that a relatively compact size for the couponassembly may facilitate ease of assessing the cathodic protection of acathodically protected structure 2. For example, embodiments of thecoupon assembly having a compact dimension or diameter (e.g., based onthe outer surface dimension of the first fitting, shown as 112 in FIGS.3 and 212 in FIG. 5 ) may encounter fewer obstructions duringinstallation. For some embodiments, Applicant has found that a couponassembly not exceeding about 0.50 inches in diameter or dimension, forexample, may make it possible for an individual technician to manuallyinstall a coupon assembly adjacent the structure 2 without the need formechanical excavation equipment. For some embodiments, Applicant hasfound that a coupon assembly not exceeding about 1.0 inch in diameter ordimension, for example, may make it possible for an individualtechnician to manually install a coupon assembly adjacent the structure2 without the need for mechanical excavation equipment. The individualtechnician may thereafter perform multiple measurements using theinstalled coupon assembly, and/or perform measurements at multiplelocations along the length of the structure 2.

For example, according to some embodiments, an example coupon assembly100 and/or 200, may be inserted into the ground (or into an aqueousenvironment) to a selected location and/or to a selected depth, suchthat the coupon assembly 100 and/or 200 is exposed in the same orsimilar soil or aqueous environmental conditions as the at leastpartially buried or submerged structure 2 being assessed. In someinstances, the selected location and/or selected depth may be in thevicinity of, or close to, a less well-protected region of the structure2. In some embodiments, to facilitate insertion of the coupon assembly100 and/or 200 into the ground, a probe rod 20 or other penetratingdevice, such as the example probe rod 20 shown in FIG. 6 , may be usedto create a pilot hole 5 (see FIG. 1 ). For example, the probe rod 20may be manually pushed into the ground using the leverage provided bygrasping portion 24. The grasping portion 24 may be configured tofacilitate a secure grip on the first rod end 26 of the probe rod 20,such that a technician may apply a downward force on the probe rod 20and/or torque on the probe rod 20 about its axis to assist with drivingthe probe rod 20 into the ground to the selected depth. In someembodiments, the grasping portion 24 may include a T-handle orT-handle-like structure, facilitating a two-handed grip on the first rodend 26 of the probe rod 20. In some embodiments, the probe rod 20 mayinclude driving tip 29 at the second rod end 27, for example, as shownin FIG. 6 , to facilitate driving the probe rod 26 into the ground orsoil 1 adjacent the structure 2. In some embodiments, the driving tip 29may be selectively removable and/or replaceable with respect to theelongate member 22 of the probe rod 20. Consistent with someembodiments, a technician may be able to use a hammer, a mallet, and/orany similar hand tools, to force the driving tip 29 to the selecteddepth. In some embodiments, once the pilot hole 5 has been created tothe selected depth and/or at the selected location, the probe rod 20 maybe withdrawn, and the driving tip 29 may be removed, exposing an openend of the elongate rod member 22 for receipt of a coupon assembly 100or 200, for example, consistent with coupon assemblies described herein.For example, using the probe rod 20 with the coupon assembly 100 or 200mounted thereto as described herein, the coupon assembly 100 or 200 maybe inserted into the pilot hole 5 (FIG. 1 ) to the selected depth andseparated from the second rod end 27 of the probe rod 20 to remain inplace adjacent the structure 2 during the assessment of the cathodicprotection of the structure 2. For the next use, a driving tip 29 may beconnected and/or secured to the second rod end 27 of the probe rod 20for use to create another pilot hole 5 at another location.

FIG. 7A and FIG. 7B are a block diagram of an example method 700 forassembling and installing an example coupon assembly, according toembodiments of the disclosure, such as those described herein, as wellas others. The example method 700 is illustrated as a collection ofblocks in a logical flow graph, which represents a sequence ofoperations. The order in which the operations are described is notintended to be construed as a limitation, and any number of thedescribed blocks may be combined in any order and/or in parallel toimplement the method.

A cathodic protection monitoring assembly 3 may include a test coupon,which may include an electrically conductive coupon, for example, asdescribed herein. When positioned, the location of the test coupon maybe selected such that the surrounding environmental conditions (soil orfluid conditions) and/or characteristics are at least similar to, orsubstantially the same as, those in the vicinity of the cathodicallyprotected structure. For example, the selected location may include soilhaving conditions and/or characteristics at least similar to native soilmore distant from the structure, or in other examples, may more closelyresemble backfill, compacted, and/or heterogeneous soils. In someembodiments, the test coupon may be positioned sufficiently close to theprotected structure for which the cathodic protection is being monitoredand/or measured, such that the location is representative of soilconditions and/or characteristics, such as, for example, temperature,pressure, water chemistry, chemical additives, and/or solids loading.

At 702, the example method 700 may include providing a hollow interiorof a test coupon with a hardenable filler (e.g., epoxy, adhesive, and/orplaster), which secures the electrical connections and/or the componentsof the coupon assembly in a fixed position adjacent the test coupon,and/or protects the interior surface of the test coupon from corrosion.Prior to providing (e.g., filling) the hollow interior with hardenablefiller, the hardenable filler may be placed in a low pressureenvironment such as a vacuum chamber to remove voids and/or air bubblesfrom the hardenable filler. The hardenable filler may thereafter besupplied to the hollow interior of the test coupon and allowed to hardenor cure.

In some embodiments, an electrolyte may be supplied to the couponassembly and hydrated. For example, in some embodiments, the examplemethod 700, at 704 may include supplying the electrolyte into an innercavity or recess at least partially defined by the coupon assembly. Insome embodiments, the coupon assembly may include a removable cap, whichmay be separated from the rest of the coupon assembly to enableinjection of the electrolyte, for example, on-site where the method isbeing performed, such as at a testing site. Thus, in some embodiments,the electrolyte may not be provided to the coupon assembly untilimmediately prior to being installed in the ground. As a result, theelectrolyte has less opportunity to leak from the coupon assembly duringstorage or transport to the location of the testing. This also mayextend the service life of the coupon assembly relative to a couponassembly in which electrolyte is added to the coupon assembly duringmanufacturing of the components of the coupon assembly, for example, ata manufacturing facility remote from the testing location. In someembodiments, the electrolyte may be injected into the inner cavity orrecess using a syringe or similar device, for example, as describedpreviously herein. The coupon assembly may be checked for leaks, andwater and/or another suitable fluid may be added to the electrolyte, orthe coupon assembly may be at least partially immersed in water, suchthat water reaches the electrolyte.

In some embodiments, when the test coupon is electrically disconnectedfrom the structure at a test station or voltage measuring device,“instant-off” potential difference measurements may be made on the testcoupon, for example, without a need to interrupt any other currentsources, including the cathodic protection current of the cathodicprotection system. The test station as described herein may includecomponents for monitoring the cathodic protection of the structure(e.g., voltages, currents, and/or other signals) such as, for example, adata logger, a computer, a network connection, etc.

In some embodiments, the coupon assembly may be relatively small. As aresult, the coupon assembly may be installed adjacent to the protectedstructure without the use of mechanical digging implements or machines,such as, for example, a backhoe or excavator. For example, due to thenature of some structures, the use of mechanical digging implements ormachines in close proximity to the structure may be prohibited and/orinadvisable to prevent damage to the structure. In some embodiments, thecoupon assembly may be limited to components having small or compactdimensions, which may permit the coupon assembly to be installed nearthe structure without the use of mechanical digging implements ormachines. This, in turn, may reduce or minimize potential measurementerrors due, for example according to some embodiments, to the relativelyclose placement of the coupon assembly to the structure, therebypotentially mitigating, minimizing, or preventing interference fromother current sources. Additionally, the small or compact dimensions ofthe coupon assembly may allow the distance between the test coupon andthe reference electrode to be reduced or minimized, for example, withoutshielding the test coupon.

With the test coupon and reference electrode in electrical communicationwith the testing device and/or test station, the potential differencebetween the test coupon and reference electrode may be measured andoutput. In some embodiments, prior to connecting the lead wires to thetesting device, the example method 700, at 706, may include manuallymeasuring and/or recording the potential difference associated with thestructure being cathodically protected, for example, using a separatereference electrode for later calibration without interrupting at leastsome of the surrounding current sources (e.g., without interrupting thecathodic protection or any other surrounding current sources). In someembodiments, these measurements may be used to determine the offset forthe potential difference measurements, which may be measured withrespect to the reference electrode of the coupon assembly. If desired,additional manual measurements of the potential difference using theseparate reference electrode may be made before and/or after theconnection of the coupon assembly to the testing device.

The example method 700, at 708, may include creating a pilot hole at apreselected distance and depth relative to the at least partially buriedor submerged structure that is protected by a cathodic protectionsystem. A probe rod including a driving tip, for example, as shown inFIG. 6 , may be used by a technician to create the pilot hole, so thatthe coupon assembly may be inserted and positioned, for example, withina preselected distance of the cathodically protected structure. Thepreselected distance may range from about 6 inches to about 5 feet, fromabout one foot to about 4 feet, from about 1 foot to about 3 feet, fromabout 1 foot to about 2 feet, or from about 1 foot to about 1.5 feet,from an outer surface or wall of the cathodically protected structure.In some embodiments, the preselected distance may range from about 2feet to about 10 feet, from about 2 feet to about 7 feet, from about 2feet to about 6 feet, from about 2 feet to about 5 feet, or from about 2feet to about 4 feet. In some embodiments, the preselected depth maygenerally correspond to a depth of the structure or a portion of thestructure.

At 710, the example method 700 further may include passing lead wiresfor the coupon assembly, contained in a wire bundle, through a rodmember of a probe rod, so the lead wires extend from an upper or firstrod end of the rod member, for example, as shown in FIG. 1 . An end ofthe wire bundle extending from the first rod end may remain above groundafter the coupon assembly is inserted and positioned in the ground at aselected location and/or depth. The end of the wire bundle extendingfrom the first rod end may be attached to a measuring device, forexample, as described previously herein.

At 712, the example method 700 further may include engaging the couponassembly with the rod cavity at an end of the probe rod. This mayinclude receiving the end of the probe rod in a recess of the couponassembly, inserting a portion of the coupon assembly into the rodcavity, or both. At 714, the example method 700 also may include holdingand securing the wire bundle with the lead wires passing through theprobe rod and applying tension on the wire bundle, which may help tomaintain engagement between the coupon assembly and the end of the proberod.

At 716, the example method 700 further may include, for example, whilemaintaining the tension, inserting the probe rod with the engaged couponassembly into the pilot hole and to the preselected depth and locationrelative to the protected structure. For example, a technician may use agrasping portion of the probe rod to push the coupon assembly to thepredetermined depth, which may correspond to the bottom of the pilothole. At 718, the example method 700 also may include releasing thetension on the wire bundle, for example, to settle the coupon assemblyat preselected depth.

The example method 700, at 720 (FIG. 7B), may include withdrawing theprobe rod from the ground while leaving the coupon assembly at thepreselected depth and location adjacent the structure. The probe rod maythereafter be completely separated from the coupon assembly, and thelead wires of the wire bundle may continue to extend from the ground atthe opening of the pilot hole.

At 722, the example method 700 also may include routing the lead wiresfrom the coupon assembly and connecting the lead wires to an electricaljunction in communication with the testing device configured tofacilitate measurement of potential differences detected by the couponassembly. In some embodiments, the electrical junction may be incommunication with a remote test station. In some embodiments, theelectrical junction may be in communication with a remote test stationvia a hard-wired communications network and/or a wireless communicationsnetwork, which may adhere to known hard-wired and/or wirelesscommunication protocols. In some embodiments, during installation, thecoupon assembly may be electrically connected to the at least partiallyburied or submerged structure and the anode of the associated cathodicprotection system, for example, such that the coupon assembly isprotected by the cathodic protection system. In some embodiments, avoltage measuring device of the test station may include one or moreswitching devices for selectively connecting and/or disconnecting areference electrode to one terminal, while selectively connecting and/ordisconnecting the structure connection from another terminal. In someembodiments, the test coupon and/or reference electrode may beindependently isolated from other components in the cathodic protectionsystem. For example, the test coupon may be energized and subsequentlyisolated from the cathodic protection system and the partially buried orsubmerged structure through a switching device, allowing a potentialdifference measurement to be made on the test coupon with respect to thereference electrode.

At 724, the example method 700 also may include taking one or morepolarized measurements of the potential difference between the referenceelectrode and the test coupon, for example, without interrupting one ormore of the surrounding current sources. For example, the potentialdifference may be sampled, and an averaged reading may be obtained. Insome embodiments, a data logger may be used to record the raw data overa period of time. In some embodiments, the data may be transmitted usinga network connection and may be stored in a remote database, forexample, with appropriate identifying information for the location ofthe structure and coupon assembly, and/or the type of protective system.

At 726, the example method 700 further may include comparing themeasured potential differences to known cathodic protection criteria forthe known structure and cathodic protection system, for example, toassess the continuing operation of the cathodic protection system. At728, the example method 700 also may include using this comparisonand/or other relevant data to determine whether (and/or to what degree)the at least partially buried or submerged structure may be corroding.

This is a continuation of U.S. Non-Provisional application Ser. No.17/886,178, filed Aug. 11, 2022, titled “ASSEMBLIES AND METHODS FORMONITORING CATHODIC PROTECTION OF STRUCTURES,” which is a divisional ofU.S. Non-Provisional application Ser. No. 17/805,801, filed Jun. 7,2022, titled “ASSEMBLIES AND METHODS FOR MONITORING CATHODIC PROTECTIONOF STRUCTURES,” now U.S. Pat. No. 11,447,877, issued Sep. 20, 2022,which claims priority to and the benefit of U.S. Provisional ApplicationNo. 63/365,102, filed May 20, 2022, titled “ASSEMBLIES AND METHODS FORMONITORING CATHODIC PROTECTION OF STRUCTURES,” and U.S. ProvisionalApplication No. 63/260,622, filed Aug. 26, 2021, titled “MINIATURE IRERROR FREE CATHODIC PROTECTION COUPON ASSEMBLY INSTALLED VIA PROBE,” thedisclosures of which are incorporated herein by reference.

Having now described some illustrative embodiments of the disclosure, itshould be apparent to those skilled in the art that the foregoing ismerely illustrative and not limiting, having been presented by way ofexample only. Numerous modifications and other embodiments are withinthe scope of one of ordinary skill in the art and are contemplated asfalling within the scope of the disclosure. In particular, although manyof the examples presented herein involve specific combinations of methodacts or system elements, it should be understood that those acts andthose elements may be combined in other ways or configurations toaccomplish the same objectives. Those skilled in the art shouldappreciate that the parameters and configurations described herein areexemplary and that actual parameters and/or configurations will dependon the specific application in which the systems, methods, and/oraspects or techniques of the disclosure are used. Those skilled in theart should also recognize or be able to ascertain, using no more thanroutine experimentation, equivalents to the specific embodiments of thedisclosure. It is, therefore, to be understood that the embodimentsdescribed herein are presented by way of example only and that, withinthe scope of any appended claims and equivalents thereto, the disclosuremay be practiced other than as specifically described.

Furthermore, the scope of the present disclosure shall be construed tocover various modifications, combinations, additions, alterations, etc.,above and to the above-described embodiments, which shall be consideredto be within the scope of this disclosure. Accordingly, various featuresand characteristics as discussed herein may be selectively interchangedand applied to other illustrated and non-illustrated embodiment, andnumerous variations, modifications, and additions further may be madethereto without departing from the spirit and scope of the presentdisclosure as set forth in the appended claims.

What is claimed is:
 1. A method for installing a cathodic protectioncoupon monitoring assembly, the method comprising: passing lead wiresfrom a coupon assembly through a probe rod, the coupon assemblyincluding an electrically conductive test coupon and a referenceelectrode; engaging the coupon assembly with a rod cavity at a distalrod end of the probe rod; tensioning the lead wires, thereby tostabilize the coupon assembly; when tensioning the lead wires, insertingthe probe rod and the coupon assembly to one or more of a preselecteddepth or a preselected distance relative to the structure; releasingtension on the lead wires; withdrawing the probe rod from thepreselected depth, thereby to leave the coupon assembly at the one ormore of the preselected depth or the preselected distance; andconnecting the lead wires to an electrical junction in communicationwith a testing device, thereby to facilitate measurement of potentialdifferences detected by the coupon assembly.
 2. The method of claim 1,wherein inserting the probe rod and the coupon assembly to the one ormore of the preselected depth or the preselected distance comprisesforming a pilot hole at a preselected distance from the at leastpartially buried structure or the at least partially submergedstructure, and then inserting the probe rod and the coupon assembly intothe pilot hole.
 3. The method of claim 1, wherein the electricallyconductive test coupon includes a hollow interior at least a partiallyfilled with a hardenable filler configured to protect the interior ofthe electrically conductive test coupon from corrosion, and wherein thecoupon assembly further includes a plug having a plug cavity, the secondfitting including a proximal end having one or more holes thatcommunicate with the fitting chamber, the proximal end of the secondfitting sized to fit at least partially within the plug cavity, andwherein the method further comprises wicking moisture from a surroundingenvironment at the one or more of the preselected depth or thepreselected distance, through the plug, to the fitting chamber via theone or more holes after inserting the probe rod and the coupon assemblyto the one or more of the preselected depth or the preselected distance.4. The method of claim 1, further comprising obtaining a calibrationmeasurement to measure a potential difference between a referenceelectrode and the at least partially buried structure or the at leastpartially submerged structure without interrupting one or moresurrounding current sources.
 5. The method of claim 1, furthercomprising: obtaining a polarized measurement of the potentialdifference between a reference electrode and the electrically conductivetest coupon without interrupting one or more surrounding currentsources, and wherein obtaining the polarized measurement comprisesaveraging a plurality of potential difference measurements over aselected time interval; comparing the potential difference between thereference electrode and the electrically conductive test coupon to knowncathodic protection criteria; and determining, based at least in part onthe comparing, whether the at least partially buried structure or the atleast partially submerged structure has corrosion associated therewith.6. The method of claim 1, further comprising: removing a cap from adistal end of the coupon assembly; filling at least a portion of thecoupon assembly with an electrolyte; and replacing the cap so assubstantially to seal the electrolyte within the coupon assembly.
 7. Themethod of claim 1, wherein the structure is at least partially buried insoil, the soil having one or more soil characteristics, and wherein thestep of inserting the probe rod and the coupon assembly to the one ormore of the preselected depth or the preselected distance relative tothe structure comprises inserting the probe rod and the coupon assemblyto one or more of a representative preselected depth or a representativepreselected distance, such that soil at the representative preselecteddepth or the representative preselected distance has representative soilcharacteristics consistent with the one or more soil characteristics,the one or more soil characteristics comprising one or more oftemperature, pressure, moisture content, chemistry, chemical additives,or solids loading.
 8. A method to install a cathodic protection couponmonitoring assembly, the method comprising: passing lead wires from acoupon assembly through a rod cavity of a probe rod, the coupon assemblyincluding: a first fitting, an electrically conductive test couponadjacent the first fitting, a reference electrode, and a second fittingpositioned between a distal end of the coupon assembly and theelectrically conductive test coupon; engaging the coupon assembly withthe probe rod; inserting the probe rod and the coupon assembly to apreselected depth; withdrawing the probe rod from the preselected depthso that the coupon assembly remains at the preselected depth; andconnecting the lead wires to an electrical junction in communicationwith a testing device, thereby to facilitate measurement of potentialdifferences detected by the coupon assembly.
 9. The method of claim 8,wherein inserting the probe rod and the coupon assembly to thepreselected depth comprises forming a pilot hole, and then inserting theprobe rod and the coupon assembly into the pilot hole.
 10. The method ofclaim 8, wherein the electrically conductive test coupon includes ahollow interior at least partially filled with a hardenable fillerconfigured to protect the hollow interior of the electrically conductivetest coupon from corrosion, and the method further comprising: formingthe pilot hole in soil with the probe rod; and injecting water throughone or more perforations in the probe rod, thereby to stabilize the soilsurrounding the pilot hole.
 11. The method of claim 8, furthercomprising: tensioning the lead wires to stabilize the coupon assemblyat the distal rod end of the probe rod; releasing tension on the leadwires; and obtaining a calibration measurement to measure a potentialdifference between the reference electrode and one or more of: (a) an atleast partially buried structure, or (b) an at least partially submergedstructure without interrupting one or more surrounding current sources.12. The method of claim 11, further comprising: obtaining a polarizedmeasurement of the potential difference between the reference electrodeand the electrically conductive test coupon without interrupting the oneor more surrounding current sources; comparing the potential differencebetween the reference electrode and the electrically conductive testcoupon to known cathodic protection criteria; and determining, based atleast in part on the comparing, whether the at least partially buriedstructure or the at least partially submerged structure has corrosionassociated therewith.
 13. The method of claim 8, further comprising:removing a cap from the distal end of the coupon assembly; filling atleast a portion of the fitting chamber with an electrolyte; andreplacing the cap so as substantially to seal the electrolyte within thefitting chamber.
 14. The method of claim 8, wherein the structure is atleast partially buried in soil, the soil having one or more soilcharacteristics, and wherein the step of inserting the probe rod and thecoupon assembly to the preselected depth comprises inserting the proberod and the coupon assembly to a representative preselected depth, suchthat soil at the representative preselected depth has representativesoil characteristics consistent with the one or more soilcharacteristics, the one or more soil characteristics comprising one ormore of temperature, pressure, moisture content, chemistry, chemicaladditives, or solids loading.
 15. A method to install a cathodicprotection coupon monitoring assembly, the method comprising: passinglead wires from a coupon assembly through a cavity of a probe rod, thecoupon assembly including: a first fitting, an electrically conductivetest coupon adjacent the first fitting, a reference electrode, and asecond fitting positioned between a distal end of the coupon assemblyand the electrically conductive test coupon, the second fittingincluding a fitting chamber configured to be at least partially filledwithin electrolyte, and the reference electrode at least partiallyinserted within the fitting chamber; engaging the first fitting of thecoupon assembly with the distal rod end of the probe rod; inserting theprobe rod and the coupon assembly to one or more of a preselected depthor a preselected distance relative to a structure; withdrawing the proberod from the preselected depth; leaving the coupon assembly at the oneor more of the preselected depth or the preselected distance during thewithdrawal of the probe rod; and connecting the lead wires to anelectrical junction in communication with a testing device, thereby tofacilitate measurement of potential differences detected by the couponassembly.
 16. The method of claim 15, wherein inserting the probe rodand the coupon assembly to the one or more of the preselected depth orthe preselected distance comprises forming a pilot hole at a preselecteddistance from the structure, and then inserting the probe rod and thecoupon assembly into the pilot hole.
 17. The method of claim 15, whereinthe electrically conductive test coupon includes a hollow interior thatis at least partially filled with a hardenable filler configured toprotect the hollow interior of the electrically conductive test couponfrom corrosion, and the method further comprising: forming the pilothole in soil with the probe rod; and injecting water through one or moreperforations in the probe rod, thereby to stabilize the soil surroundingthe pilot hole.
 18. The method of claim 15, further comprising:tensioning the lead wires to stabilize the coupon assembly at the distalrod end of the probe rod; releasing tension on the lead wires; andobtaining a calibration measurement to measure a potential differencebetween the reference electrode and one or more of: (a) an at leastpartially buried structure, or (b) an at least partially submergedstructure without interrupting one or more surrounding current sources.19. The method of claim 18, further comprising: obtaining a polarizedmeasurement of the potential difference between the reference electrodeand the electrically conductive test coupon without interrupting the oneor more surrounding current sources; comparing the potential differencebetween the reference electrode and the electrically conductive testcoupon to known cathodic protection criteria; and determining, based atleast in part on the comparing, whether the at least partially buriedstructure or at least partially submerged structure has corrosionassociated therewith.
 20. The method of claim 19, wherein obtaining thepolarized measurement comprises averaging a plurality of potentialdifference measurements over a selected time interval, and the methodfurther comprising: removing a cap from the distal end of the couponassembly; filling at least a portion of the fitting chamber with anelectrolyte; and replacing the cap so as substantially to seal theelectrolyte within the fitting chamber, and wherein the coupon assemblyfurther includes a plug having a plug cavity, the second fittingincluding a proximal end having one or more holes that communicate withthe fitting chamber, the proximal end of the second fitting sized to fitat least partially within the plug cavity, and wherein the methodfurther comprises wicking moisture from a surrounding environment at theone or more of the preselected depth or the preselected distance,through the plug, to the fitting chamber via the one or more holes afterinserting the probe rod and the coupon assembly to the one or more ofthe preselected depth or the preselected distance.